RBI LCD-I0M-8R, Installation And Operation Instructions Manual

Page 1: ...tion dust and particulate particularly drywall dust will cause contamination of the burner resulting in possible severe personal injury death or substantial property damage The boiler can only be operated with a dust free air supply Follow the instruction manual procedures to duct air to the boiler air intake If the boiler has been contaminated by operation with contaminated air follow the instruc...

Page 2: ...jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 If the information in this manual is not followed exactly afireorexplosionmayresultcausingproperty personal injury or loss of life Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance What To Do If Yo...

Page 3: ...r is level from front to back and from side to side Use metal shims to level the boiler water heater Electrical and electronic components must also be protected from exposure to water during operation and maintenance DO NOT install this boiler water heater in a location that would subject any of the gas ignition components to direct contact with water or excessive moisture during operation or serv...

Page 4: ...ntsubjectedto anegativepressureunlesstheairintakeisconnectedto the outdoors Failure to comply with this warning can result in excessive levels of carbon monoxide causing severe personal injury or death All Air From Inside The Building IftheLCDistobelocatedinaconfinedspacetheminimumclearances listedinTable1mustbemaintainedbetweenitandanycombustible construction When installed in a confined space wi...

Page 5: ...ical venting using a masonry chimney system and inside air Figure 3 Horizontal venting using inside air 305 TO 457 127 TO 254 VENT PIPE DIAMETER 5 TO 10 12 TO 18 MINIMUM VERTICAL RISE OFF THE TOP OF UNIT A IN mm FT mm 12 24 305 610 1 5 FT 0 5 m 1 4 IN PER F00T 20 mm m Table 2 ...

Page 6: ...less than 1 in2 per 7 000 Btuh 310 mm2 per kW up to and including 1 million Btuh plus 1 in2 per 14 000 Btuh 155 mm2 per kW in excess of 1 million Btuh Intake Air Option General Guidelines This configuration provides combustion air directly to the boiler waterheater sairintakeusingadedicatedpipetoobtaincombustion airfromtheoutdoors Combustionaircanbedrawninhorizontally through an outside wall or ve...

Page 7: ...ngle or multiple units exhaust and combustion air terminals must be installed on the same plane outside wall in order to prevent pressure differences due to prevailing winds In cold climates double wall or insulated inlet pipe recommended to prevent condensation 1 5 FT 0 5 m 2 IN 5 0 cm 6 7 8 9 Y e c 0 1 2 3 4 5 6 7 8 9 0 5 10 15 20 Horizontal Distance X Y e c n a t s i D l a c i t r e V 2000 Larg...

Page 8: ... and venting metal chimney system shown Locate exhaust terminal downwind from air intake to reduce potential for flue gas recirculation Figure 7 Combination air intake and venting masonry chimney shown 10 FT 3 1 m 4 FT 1 2 m 5 FT 1 5 m 1 5 FT 0 5 m 5 1 2 FT 1 7 m 1 5 FT 5m 10 FT 3 1 m 3 FT 1 m ...

Page 9: ...o avoid spillage into the room of dangerous flue gas containing carbon monoxide the opening in damper must never face against the flow of flue gas VENT SYSTEM OPTIONS The LCD may be vented the following ways 1 Vertical Chimney Venting Negative Pressure Category I uses an approved metal chimney system or properly lined masonry chimney Combustion air is obtained from the space in which the unit is i...

Page 10: ...y chimneys the connector must terminate flush with the inside of the chimney flue Figure 2 Fasten each single wall vent connection with at least 3 corrosion resistant sheet metal screws Never install a vent pipe having a diameter different than that of the boiler water heater flue collar Failure to comply with this warning can result in excessive levels of carbon monoxide which can cause severe pe...

Page 11: ...zontal vent systems should be as short and straight as possible Whenhorizontalventrunsexceed5ft 1 5mtheymustbesupported at3 ft 0 9 mintervalswithoverheadhangers Theventsystemmust be pitched down toward the vent terminal 1 4 in ft 20 mm m If any part of a single wall metal vent system passes through an unheatedspaceitmustbeinsulatedwithinsulationratedfor400 F 204 C Horizontal vent systems shall ter...

Page 12: ...isonhorizontalequiconviennent ets assurerquelesystèmeestexemptd obstruction d étranglement de fruite de corrosion et autres défaillances qui pourraient présenter des risques c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connectedtothecommonventingsystemarelocatedandother spacesofthebuilding Turnonclothesdryersandany...

Page 13: ...mproper piping of this boiler water heater will void themanufacturer swarrantyandcancauseboilerfailure resulting in flooding and extensive property damage Excessivewaterhardnesscausingscalinginthecopper heat exchanger tubes is NOT covered under the manufacturer swarranty Excessivepittinganderosion of the internal surface of the copper heat exchanger tubes is NOT covered under the manufacturer s wa...

Page 14: ...ing Figure 10 Relief valve piping Never install any type of valve between the boiler waterheaterandthereliefvalveoranexplosioncausing extensive property damage severe personal injury or death may occur Flow Switch Theflowswitchsuppliedwiththeboiler waterheatermustbewired to the terminal strip in the control panel to prevent the boiler from firing unless there s adequate water flow through the unit...

Page 15: ...rtemperatures lessthan125 F 52 Cmustbeisolatedfromthesesystemstoprotect the boiler Variable Water Flows Figure 11 shows a typical primary secondary piping system A dedicated pump is used to maintain a constant water flow through the boiler This boiler pump is sized to overcome the head loss of the boiler and near piping while supplying the flow rate required to maintain the desired temperature ris...

Page 16: ...st to lower desired temperature above Temp Min 4 Check after system operating temperature has stabilized Make final adjustments 5 Follow same adjustment procedure for sealed combustion H 3 Rev 6 NOTES 1 Boiler circuit piping must be sized large enough to handle maximum flow through unit 2 Boiler pump sized to boiler design flow requirements 3 All boilers furnished with factory mounted outlet water...

Page 17: ...als supplied 5 Secondary loop pipe diameter must be sized large enough to handle maximum flow through all units Notice These drawings show suggested piping configuration and valving Check with local codes and ordinances for specific requirements Figure 12A Low temperature piping with thermostatic valve See notes and adjustment procedures Figure 13 Multiple Boiler Piping See Notes Operated Valve Ai...

Page 18: ...en 8 and 18 and by maintaining the pH between 5 and 9 Follow the conditions listed underNORMALinthetable Insomeareasofthecountryadditional precautions must be observed due to unusual characteristics of the local water supply Call the nearest RBI representative for details ToproperlysizethepumpagrainhardnessandpHtestmustbetaken attheinstallationsitebeforetheorderisplaced Properpumpsizing will impro...

Page 19: ...Finned copper tube gas boilers water heaters Boiler Manual 19 Table 9A LCD Heat exchanger selection graph Table 9B LCD Pumping performance requirement ...

Page 20: ... drawings show suggested piping configuration and valving Check with local codes and ordinances for specific requirements Operated Valve Air Vent Pressure Switch Aquastat Union Gas Pressure Regulator Automatic Thermometer Flow Switch Pressure Relief Valve Reducing Valve Self Operated Check Valve Pressure Valve Pump Motorized Valve Solenoid Ball Valve Bufferfly Valve Angle Valve Valve Globe Valve B...

Page 21: ...th LP gas Table 10 Gas pipe capacity Maximum pipe capacity in ft3 hr based on 0 60 specific gravity gas at a pressure of 0 5 psig or less and a 0 3 WC pressure drop Nominal Iron Pipe Size Pipe length in feet 10 20 30 40 50 60 80 100 150 Maximum gas volume of pipe ft3 hr 3 4 278 190 152 130 115 105 90 79 64 1 520 350 285 245 215 195 170 150 120 1 1 4 1050 730 590 500 440 400 350 305 250 1 1 2 1600 ...

Page 22: ...and the instructionscontainedinthismanual Donotattempt to operate this boiler water heater if it has not been installed in accordance with the guidelines set forth in this manual Failure to comply with this warning canresultinextensivepropertydamage severepersonal injury or death Should overheating occur or the gas supply fail to shut off turn off the manual gas control valve to the appliance Do n...

Page 23: ...ition A single pressure switch is used on the standard models One low fire and one high fire pressure switch is used when the two stage option is employed The low fire pressure switch serves to shut down gas flow if there isablockedflueorinletconditionduringlowfireoperation Similarly the high fire switches will shut down gas flow if there is a blocked flue or inlet condition during high fire opera...

Page 24: ... blower s pump s and optional power venter will remain on during this time 5 On CSD 1 equipped units the blower s and optional power venter will shut down and the boiler water heater will lock if the second ignition trial fails The unit must then be manually reset by depressing the reset button on the left jacket panel 6 On non CSD 1 equipped units the FSM will wait 10 minutes after the second uns...

Page 25: ...tempt then begin the ignitionprocessdescribedinstep3above TheFSMwillcontinue to cycle the unit through steps 3 4 and 6 until the unit lights or the demand for heat is removed Main Burner Once the pilot is proven the FSM sends 24VAC to its MV terminal energizing the safety and low fire side of the main solenoid valves Normal Operation Staging is controlled by the return water aquastat Relays R2 and...

Page 26: ...in Suives les instructions du fournisseur Si vous ne pouvez rejoindre le fournisseur appelez le service de incendies C Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control that has been under water N utilisez pas cet appareil s il a été plongé dans l eau ...

Page 27: ...hes for proper operation before placing boiler on line LP Nat Minimum in WC 11 7 Maximum in WC 14 14 Measure pressure when the boiler is firing at full rate Low gas pressurecouldindicateundersizedgaslineorinsufficientgassupply Static and operating gas pressure required at the gas valve inlet is between 7 in WC and 14 in WC for natural gas and 11 in WC and 14inWCforpropane Ifthegaspressureisaboveth...

Page 28: ...sure that the gas piping is fully purged of air Inspect the ignition system and ensure that it is operating properly 2 Totesttheignitionsafetyshutoffdevice closethemanualshutoff valve in the gas supply line Within 5 seconds of main burner flame extinction the main gas valve solenoid should close with an audible noise After 10 seconds the module should lockout and the trial for ignition end After 5...

Page 29: ...essure and counter clockwise to decrease it 5 Replace the pressure regulator adjustment screw cap Gas Pressure Adjustment The maximum inlet gas pressure listed on the rating plate must not be exceeded or damage to the boiler water heater may occur voiding the warranty The minimum supply pressure listed on the rating plate is for input adjustment The manifold pressures should match those listed in ...

Page 30: ...water outlet piping to prevent the boiler waterheaterfromfiringwithoutadequatewaterflowthrough the heat exchanger Low Water Cutoff If the boiler is to be installed above radiation or if required by other codesorregulations installalowwatercutoffinappropriatepiping Wiretheswitchandanyexternalcontrolsinseriestothe Interlock contacts in the control box see the wiring diagrams included with the unit f...

Page 31: ...tioncomponentsarefreefromdust soot dirt corrosionorother deposits that would impair the boiler water heater s performance Refer to page 36 for component identification Burner Inspection And Removal Figure 20 1 Close the manual shutoff valves in the gas supply lines and turn off electrical power to the boiler water heater 2 Remove the front jacket panels 3 Disconnectthemanifoldgaspipingatthegroundj...

Page 32: ...the heat exchanger out of the unit 10 Remove the V baffle straps and V baffles 11 Thoroughly inspect the heat exchanger for signs of damage If there is no damage clean the heat exchanger with water from a high pressure hose Use a soft bristle brush if necessary Nevercleantheheatexchangerwhileit sintheboiler water heater or the combustion chamber will be destroyed 12 Sagging or distorted heat excha...

Page 33: ...harge water at normal system pressure If it does contact a qualified service technician to have it inspected NEVER try to clean or repair the relief valve If the valve fails to operate properly have it replaced 5 Theaquastathighlimitcontrolsthemaximumwatertemperature in the boiler It should be set at least 20 F 11 C above the operater setpoint If the water temperature reaches the set temperature b...

Page 34: ...r venter interlock not wired 1 Wire power venter interlock as shown in connection diagram 6 No Power To Blower s 1 Blower s not plugged in 2 Defective blower timer TD3 3 Blower s malfunctioning 1 Plug in blower s 2 Replace blower timer TD3 3 Replace blower s 7 Unit Does Not Spark 1 Incorrect spark gap or shorted ignitor lead 2 Bad ground on flame sense module 3 Defective flame sense module 4 Low a...

Page 35: ...et too low 1 Increase control temperature setting 11 Unit Consistently Shuts Down On High Limit 1 High limit set to low 1 Increase high limit setting 12 Bad Combustion High CO Yellow Flames 1 Insufficient air 2 Dirty inlet air filter 3 Too much air 1 Check CO CO2 adjust blower inlet damper s to increase airflow Check for plenum air leakage from lower front jacket panel seams repair as necessary 2 ...

Page 36: ...Finned copper tube gas boilers water heaters Boiler Manual 36 Figure 23 Exploded view Repair parts ...

Page 37: ...12 12 14 14 Manning Glass Tape per ft 66 0105 4 6 8 14 14 16 16 18 18 PVC Gasket Foam per ft per roll 50 66 0103 50 50 50 50 50 50 50 50 50 2 Blanket Insulation per sq ft 05 0200 20 22 24 30 34 36 36 44 46 Red Silicone Gasket per ft per roll 50 06 0146 50 50 50 50 50 50 50 50 50 15 Combustion Chamber Lower Front Panel 03 1963 1 03 1964 1 03 1965 1 03 1967 1 03 2171 1 03 1968 1 03 1969 1 03 1970 1 ...

Page 38: ...0 3091 1 70 3092 1 29 Main Orifice NG 10 0087 7 9 13 15 10 0130 17 19 23 27 Main Orifice LP 10 0088 7 9 13 15 17 19 23 27 Main Orifice NG 10 0115 5 Main Orifice LP 10 0116 5 NS Pilot Orifice NG 10 0089 1 1 1 1 10 0132 1 1 1 1 Pilot Orifice LP 10 0090 1 1 1 1 1 1 1 1 Pilot Orifice NG 10 0093 1 Pilot Orifice LP 10 0120 1 30 Burner Tube 10 0275 5 7 9 13 15 17 19 23 27 Burner Tube w hole for Pressure ...

Page 39: ...Iron Headers 70 3003 1 70 3004 1 70 3006 1 70 3007 1 70 2832 1 70 2833 1 70 2834 1 70 2835 1 Heat Exchanger Assembly Copper 70 3024 1 Cast Iron Headers 70 3025 1 70 3026 1 70 3028 1 70 3029 1 70 2852 1 70 2853 1 70 2854 1 70 2855 1 Individual copper cupronickel tubes available for field repair model and serial number required Tube Expansion Tool 30 0761 1 1 1 1 1 1 1 1 1 Heat Exchanger Assembly Cu...

Page 40: ...066 1 70 3067 1 70 3069 1 70 3070 1 70 2917 1 70 2918 1 70 2919 1 70 2920 1 NS Heat Exchanger V Baffles 03 2011 36 03 2012 7 36 03 2013 7 03 2014 7 03 2016 14 03 2017 18 18 03 2019 18 34 Hold Down Clips 03 2164 14 14 14 28 36 36 72 36 72 NS Heat Exchanger Support Channel 03 2022 1 03 2023 1 03 2024 1 70 3081 2 70 3082 2 70 3083 2 70 3085 2 70 3086 2 Model Size with Item Quantities Below Heat Excha...

Page 41: ...Limit LB 14 0009 1 1 1 1 1 1 1 1 1 High Limit LW 14 0008 1 1 1 1 1 1 1 1 1 NS High Limit Well 3 8 x 3 13 0104 1 1 1 1 1 1 1 1 1 NS Operator LB 14 0007 1 1 1 1 1 1 1 1 1 Operator LW 14 0010 1 1 1 1 1 1 1 1 1 Operator T6031A pool heater 14 0003 1 1 1 1 1 1 1 1 1 45 Firing Valve 3 4 11 0461 1 Firing Valve 1 11 0456 2 2 Firing Valve 1 1 4 11 0457 2 2 Firing Valve 1 1 2 11 0458 2 2 2 Firing Valve 2 11 ...

Page 42: ...13 0302 2 2 2 2 2 1 1 1 1 NS Flow Switch 14 0203 1 1 1 1 1 1 1 1 1 Flow Switch Outdoor 14 0205 1 1 1 1 1 1 1 1 1 Flow Switch Potter 14 0201 1 1 1 1 1 1 1 1 1 Flow Switch Outdoor Potter 14 0202 1 1 1 1 1 1 1 1 1 NS Thermometer Well 3 8 x 3 13 0104 1 NS Thermometer Well 3 8 x 4 13 0105 1 1 1 1 1 1 1 1 54 Main Board Assembly On Off 70 2927R 1 1 1 1 1 1 1 1 1 Main Board Assembly 2 Stage 70 2928R 1 1 1...

Page 43: ...rmination Hood 14 09 0141 1 1 1 NS Air Intake Hood 6 09 0102 1 Air Intake Hood 8 09 0103 1 1 Air Intake Hood 10 09 0104 1 Air Intake Hood 12 09 0105 1 1 1 1 1 NS Barometric Damper 6 09 0405 1 Barometric Damper 7 09 0409 1 Barometric Damper 8 09 0404 1 Barometric Damper 10 09 0403 1 Barometric Damper 12 09 0401 1 1 Barometric Damper 14 09 0402 1 1 1 NS Rack Assembly 70 2886 1 70 2888 1 1 70 2890 1 ...

Page 44: ...per service clearance provided Is vent vertical through the roof Outdoor air sensor installed wired Is vent through the wall Are units racked Is power vent installed and wired Is rack assembled tightly Sealed combustion No holes screwed into cabinet ELECTRICAL WIRING CONTROL Boiler Supply Voltage External BMS System Boiler Pump Supply Voltage Utilize Boiler BTC For Control Voltage Down Stream of T...

Page 45: ... CSD 1 Pump Delay Combustion Air Damper Power Vent Proving Switch Barometric Damper COMMISSIONING THE UNIT Customer Instructed Yes No All Covers Replaced Yes No Wiring Secure Tight Yes No Customer Given Manual Yes No Cabinet Air Leaks Yes No Gas Leaks Detected Yes No Unit Cycled Min of 15 X Yes No Temp Set Per Customer Yes No Left Maintenance Instruction Yes No Commissioned By Signature Date The d...

Page 46: ...for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS g INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless upon inspection the inspector observes carbon monoxide d...

Page 47: ... the manufacturer s warranty Excessive pitting and erosion on the inside of the heat exchanger tubes caused by high water velocity through the tubes and is not covered by the manufacturer s warranty See Installation Instructions for proper pump performance Chemical corrosion no corrosive chemical freon dry cleaning chemicals degreasing liquids chlorine or any chemicals that produce hydrochloric ac...

Page 48: ...260 North Elm Street 7555 Tranmere Drive Westfield MA 01085 Mississauga Ontario L5S 1L4 Canada Phone 413 568 9571 Phone 905 670 5888 Fax 413 568 9613 Fax 905 670 5782 www rbiwaterheaters com ...